Method of and mold for casting vitreous closets in two parts



Oct. 10, 1939. c. w. LAscHENsKl METHOD GP AUD HOLD POR CASTING VTTREOUS CLOSETS IN TWO PARTS Filed March 16, 1957 4 Sheets-Sheet l Oct l0. 1939 c. w. LASCHENSKI 2,175,730

METHOD 0F ND HOLD FOR CASTING VITREOUS CLOSETS IN TWO PARTS Filed-March 16, 1937 4 Sheets-Sheet 2 Oct. 10, 1939. C, w LASCHENSN 2,175,730

HETHOD OF AND HOLD FOR CASTING VITREOUS GLOSETS IN TWO PARTS Filed March 16, 19157 4 Sheets-Sheet I5 IN1/EN TOR.

BY 3,5%, @77% Cam M1 ATTORNEYS.

Oct. 10, 1939. c. w. LAscHr-:Nsm

METHOD 0F AND IOLD POR CASTING VITREOUS CLOSETS IN TWD PARTS Filed March 15, 1937 4 Sheets-Sheet 4- INVENTOR.

www WMM da, ATTORNEYS.

Patented Oct. 10, 1939 PATENT OFFECE METHOD 0F AND REGLE) FOR CASTING VITREGUS CLOSETS IN TIN() PARTS Charles W. Laschenski, Trenton,

N. J., assigner,

by mesne assignments, to American Radiator &

Standard Sanitary Corperation,

New York,

N. Y., a corporation of Delaware Application March 16,

9 Claims.

My present invention relates to the art of making vitreous closets and, more especially, to a method of and molds for casting such closets in two parts.

Vitreous closets of the nature here involved have been heretofore cast by various procedures and in various types of molds, but insofar as I am aware all such prior procedures and molds have involved the casting of the vitreous closets in at least three or more separate parts and then uniting these parts. For example, in accordance with one previous procedure the sides and foot of the closet were cast separately in one set of molds, the rim was cast separately in another set of molds, and the plate or tongue was cast separately in a third set of molds. Such a method usually requires 9 mold parts and at least two uniting operations. Such prior procedure also necessitated considerable work in the finishing operations and, in addition, the casting operations themselves were actually relatively difiicult to carry out. Experience has shown that the greater the number of molds and operations the greater the percentage of imperfect articles produced, and hence the greater the cost per nished perfect unit.

It is, accordingly, one of the objects of my present invention to simplify the procedure in casting vitreous closets and to reduce the num'- ber of mold parts required.

Another object of my invention includes a reduction of the number of uniting operations involved in casting a vitreous closet and conse.- quently in reducing the number of imperfect articles as well as decreasing the cost per finished unit.

Another object resides in the provision of a set of mold parts which will make possible the accomplishment of the foregoing objectives.

Further objects and advantages will be understood by those versed in this art or will be apparent or pointed out in the following description.

In the accompanying drawings forming a part hereof:

Figure l is an elevational view in perspective of an outside mold and foot core having a longitudinal half-casting therein;

Fig. 2 is a perspective view of the core adapted to be assembled with the mold of Fig. 1 and showing how th-e foot core cooperates therewith;

Fig. 3 is a view similar to Fig. l for a modified type of closet;

Fig. 4 is a view similar to Fig. 2 for the closet of the type shown in Fig. 3;

1937, Serial No. 131,168

(Cl. 25m-129) Fig. 5 is a perspective elevational view of a mold adapted to produce a transverse half-casting and showing such a casting therein;

Fig. 6 illustrates the body and foot cores adapted to cooperate with the mold of Fig. 5;

Fig. 7 is a view similar to Fig. 5 of the other transverse half mold and casting; and

Fig. 8 illustrates the body and foot cores for Fig. 7.

Similar numerals designate corresponding parts throughout the several views of the drawings.

I have discovered not only that there are certain difliculties and disadvantages in connection with the casting of vitreous closets by known procedures and with known molds, but also that these defects and disadvantages can be largely, if notl entirely,v eliminated. In one commonly used method, vitreous closets and similar articles are cast in three parts, viz., the foot and sides, the rim, and the plate. In many cases the foot and sides are not cast integrally, and in such cases my present invention has still further features of advantage as will be understood. Where the vitreous closet is cast in the three parts just enumerated, each such part is cast in a separate set of molds suitably constructed and configured in accordance with the particular design of the closet to be produced. The minimum number of mold parts in prior procedures is usually nine (9).

As is well known in the art, each mold part is composed of a suitable composition such as plaster of Paris or the like Which is kept under predetermined conditions of humidity so that not only will the moisture content of the molds be denitely known but the molds will have the capacity of absorbing additional moisture at a definite known rate. This is taken advantage of by assembling suitable molds of such character and iilling them with liquid slip of the desired composition and from which the closet or other article is to be cast. Under such conditions the mold will immediately begin to absorb moisture from the liquid slip and, as already indicated, the rate at which the moisture will be absorbed is definitely known. Therefore, the liquid slip is left in the molds for a predetermined length of time after which the channels in which the liquid slip is contained are drained of excess slip. Inl other words, liquid slip is poured into the assembled molds which absorb water from the slip, thus causing a layer of clay to adhere to the inner mold surfaces. The thickness of this layer of clay is controlled by the time of casting and the degree of dryness of the molds. After the required thickness has been attained the liquid slip is drained olf. Thus, after the excess liquid slip is drained, the casting remains on the mold walls but it is, of course, not strong enough to be removed froni the molds so it is left in the molds for a length of time determined by experience. When each of the separate castings dries or hardens sufficiently so that it is still somewhat tacky, then the parts are united appropriately and the casting is still sufficiently soft so as to form a union at the meeting surfaces. Each such union produces a more or less visible seam in the nished closet. The closet or other casting is then suitably finished in accordance with known practice such as by suitable drying, baking, and curing operations.

The foregoing procedure is one which, while representing a high development of the art, still leaves much to be desired in casting operations for reasons indicated above. It will be noted in particular that three separate castings are made and formed into a complete closet by two uniting operations. My present invention reduces the uniting operations to one single operation and, at the same time, both reduces the number of mold parts required and decreases the cost of each finished unit while at the same time increasing the percentage of perfect units produced. My present method makes use of substantially the same fundamental procedure as that set forth above as to the composition of the molds and the formation of the` castings therein. However, instead of casting a vitreous closet in three or more parts I make it possible to cast the same in only two parts. These two parts require only one uniting operation and not over seven (7) mold parts as will be evident from the present disclosure.

According to my invention I cast a vitreous closet in two halves or in two portions, each of which is approximately one half of the entire closet. These halves may either be longitudinal halves, as indicated in Figures l to 4 inclusive, or they may be transverse halves, as indicated in Figures 5 to 8 inclusive.

In Figures l and 2 I show how, according to my invention, I can cast a longitudinal half of a vitreous closet of the wash-down type, it being appreciated that Figures 1 and 2 illustrate how to make only one half of the` closet but that the molds and cores lor making the other half are, of course, identical with Figures l and 2 but of opposite hand. In Figures 3 and 4 I have illustrated how, in accordance with my invention, I can cast a longitudinal half of a closet of the reverse trap and siphon jet type. In Figures 5 and 6 I have illustrated how, in accordance with my invention, I can produce the transverse rear half of a vitreous closet and, in Figures 7 and 8, how I produce the transverse front half thereof.

Referring specically to Figures l and 2, the numeral IQ indicates a mold in which a longitudinal half-casting can be produced, the casting being indicated by the numeral II. This mold is made of any suitable composition which is maintained, when not in use, under predetermined humidity conditions and may be composed, for example, of plaster of Paris or other suitable composition. This mold is so congured on its concave surfaces as to produce a casting of the desired shape. As will be observed by referring to Figures l and 2, the mold and core are so complementarily shaped at their upper ends as to form the rim of the casting. The mold IU is cut away as shown at I2 at the left-hand side of Figure l to provide the casting with means for connection with a suitable connecting pipe. The bottom portion of the mold is substantially of the same shape as the bottom of the casting to be made and is provided with a foot core I3, shown in section. Numeral It indicates a mold for a foot overcast hereinafter referred to more fully.

The mold IU is also provided with a filling aperture I5 by means of which liquid slip of the desired composition is filled into the mold at the proper time.

Casting or lling holes occur also at the points marked I5a, |519, and I5c, it being understood that filling apertures are located wherever necsary to make sure that slip is present to ll all cavities and to form a casting in all desired parts or" the mold. The location of the filling apertures varies with the particular casting as will be understood. The numerals Ilia, Ib, and IEC indicate drain holes so that all excess slip may be removed at the proper time and these, too vary in location with the particular casting. Plaster pins, not shown, are used to make the apertures Ila and I'Ib in the underside of the rim in usual manner.

Figure 2 illustrates the core I8 which is used in cooperation with the mold I5 and in general this core is provided with configurations complementary to mold ID when the mold and core are assembled. The semi-circular projection IS on core I8 fits into cut-away portion I2 of mold IG, and at the bottom of core I8 is shown how the foot core I3 interts therewith. The surfaces of the core I8 between which and the mold walls the casting is formed may be rendered impervious at any desired points so that no casting will be formed at such points but the construction and arrangement is such that the spacing between the mold and core surfaces when assembled is approximately equal to the thickness of the casting which is desired. A proper registration by the mold and core is insured by the provision of depressions 20 on the mold surfaces and intertting proturberances 2l on the core surfaces. Thus the mold, core and foot core are assembled on a bench as will be understood from the foregoing and liquid slip is poured into the spaces therebetween not only via filling aperture I5 but by additional apertures which are provided at the points IEa, ll), and |50 in order to insure that all cavities between the mold and core are filled with slip. The foot core is provided with an overcast mold I4 which substantially surrounds the circular opening '2.2 which is adapted for connection with a suitable pipe or the like. When the liquid slip has remained between the parts for a predetermined length of time, excess slip is then drained out and for this purpose I provide drain holes as indicated by the numerals Ita, and IED, and i60, and these are so disposed as to prevent any excess liquid slip from being entrapped. After the removal of the excess slip the casting is allowed to set or harden, but while it is still tacky another half-casting which has been simultaneously made in the same manner as the one already described is united with the first half-casting and the two together form a complete closet which requires no further operations except the usual finishing operations practiced on castings of this nature.

From the foregoing it will be evident that there are seven mold parts, namely, two molds like that number-ed I0, one being the opposite of the other, two body cores like that numbered I8, each being adapted to cooperate with a mold I0, two foot cores, like that indicated by the numeral I3, and one foot overcast mold I4. It will likewise be evident that since the casting is made in only two portions only one uniting operation is ree quired and this is carried out in the conventional manner known to this art by placing the two tacky half-castings together so that they unite nd give the appearance of a one piece article. In dening the mold. I as being such as will produce a half-casting, I wish it to be understood that the mold may be slightly more or slightly less than one-half. In other words, in connection with some closets it is better judgment and practice to make the longitudinal dividing line at one side of the center line and this variation forms a part of my present in- Vention.

Referring speciically to Figures 3 and 4, it will be apparent that substantially the same considerations apply as in connection with Figures l and 2 since Figures 3 and 4 differ substantially only in that the mold parts are configured to produce a diierent type of closet, namely, the so-called reverse trap or siphon jet closet. The somewhat different congurations to be imparted to the casting require certain variations in the locations of the filling apertures and drain holes but otherwise the invention is the same as in Figures l and 2, and hence need not be described in detail. Briefly, 23 indicates the half-mold and 24 the casting which is made therein; 25 represents the foot core configured to interft with the bottom of mold 23; 25 is the body core for mold 23 and 25 indicates how the foot core 25 cooperates therewith, it being understood, as was the case in connection with Figure 2, that core 25' is not actually in place as shown in Figure 4 but has merely been thus shown for illustrative purposes. Projection 21 on core 26 rits into recess 28 on mold 23. Similarly, proper registration of the mold and core is assured by depressions 29 and protuberanc-es 3U. Suitable lling holes, such as that indicated at 3|, and drain holes are provided as will be understood from Figures l and 2. Foot mold overcast 32 is provided for strengthening purposes and for building up a thicker casting around hole 33. The procedure for casting is the same as that described in connection with Figures 1 and 2.

As I have pointed out above, I am not restricted to casting a closet in two longitudinal or substantially longitudinal halves as my invention also includes casting the closet in two transverse or substantially transverse halves. Such a modification is illustrated in Figures 5 to 8 inclusive, where Figure 5 illustrates a mold 35 adapted to produce the rear half of the closet and Figure '7 a mold 36 adapted to produce the front half of the closet and Figures 6 and 8 respectively illustrate body and foot cores 31 and 3S to be used therewith. In Figure 5 the half mold 35 is provided with lling apertures to which are connected suitable lling spouts, Tunnels, or the like 39 and the remainder of the mold is so congured as to produce the desired configuration of casting 40 therein. As before, the core 3l of Figure 6 (only 1/2 is shown) is suitably assembled with the mold 35 of Figure 5, and the casting made by the same procedure as set forth in connection with Figures 1 and 2. The numeral 40 indicates a typical casting formed in such a mold and is included in the figure for the sake of clarity. Numeral 4l indicates the foot core for mold 35, and 42 the foot core for mold 36. The rear half and the front half castings are made at the same time and then united by a single uniting operation as explained above. In connection with Figures 5 to 8 inclusive, I wish it also understood that the transverse line of division need not be precisely at the transverse center as, depending upon the particular closet, the dividing line may be appropriately selected.

My invention therefore consists primarily in a method or procedure whereby a closet may be cast in two portions which can be subsequently united at the proper stage in the proceedings by a single operation. This reduction in the number of uniting operations not only lessens the cost per finished unit but simpliiies and expedites the casting operations themselves and production is thereby increased. At the same time, this procedure requires less manual labor and less skilled labor and thereby also effects an appreciable saving. Again, the reduction of mold parts to seven 4eiiects economy of operation and procedure which are reflected in the ultimate cost of the finished unit.

In carrying out the present procedure, the left side mold and cores are clamped together and the overcast is placed in the foot. The casting is then made therein. After a predetermined length of time excess slip is drained 01T. The cores are then drawn out, thus forming a complete half section of the closet. The right half is cast in the same way at the same time. The rim is then punched and the two half sections, still in the molds, are placed upside down on a level surface, such as a bench or suitable character, and stuck together or united. The molds are then turned upright and removed leaving the complete casting on a setter. Before the uniting operation a rubber balloon-like member 43 is inserted in the trap-forming portions of the castings. After uniting, the balloon is iniiated thus pushing against the seam which forms the joint and hence attening out the seam to produce a clean smooth trap way. After the complete casting becomes hard enough, the balloon is deated and removed.

Similar procedure is carried out in connection with the modifications of Figures 5 and 8 as will be understood.

I wish to make it clear, however, that I am 5 for each type an appropriate longitudinal or transverse line of division is previously determined upon and the location of the filling apertures and drain holes is suitably chosen.

While I have described and illustrated my new procedure in connection with vitreous closets I may also utilize such procedure in connection with other vitreous articles susceptible of production in the same or similar manner.

Having thus described the invention, what I claim as new and desire to secure by Letters Patent is:

l. A method of making vitreous closets which comprises separately making two vitreous castings each of which constitutes approximately one-half of a closet, inserting a deated rubber balloon-like member in the trap-forming portions of one of the castings, uniting the castings, inflating the balloon-like member in situ to a casting-supporting condition, and, after the castings become suiiciently hard, deflating and removing the balloon-like member, thereafter suitably iinishing the closet.

2. A 7-part set of molds for casting vitreous closets in two parts comprising a left half mold, a body and a foot core therefor, a right half meld, a body and a foot core therefor, and a foot overcast, said molds being so constructed and congured to produce two separate half closets.

3. A 'I-part set of molds for casting vitreous closets in two longitudinal halves comprising a left half mold, a body and a foot core therefor, a right half mold, a body and a foot core therefor, and a foot overcast, said molds being so constructed and configured as to produce two separate half closets.

4. A 7-part set of molds for casting vitreous closets in two transverse halves comprising a front half mold, a body and a foot core therefor, a rear half mold, a body and a foot core therefor, and a foot overcast, said molds being so constructed and congured as to produce two separate half closets.

5. A set of molds for casting a half-closet section comprising a half-mold, a body core and a foot core therefor, the half-mold and cores being so constructed and configured as to form between them spaces in the shape of the casting to be made approximately equal to the casting itself.

6. A set of molds for casting a half-closet section comprising a half-mold, a body core and a foot core therefor, the half-mold and cores being so constructed and congured as to form between them spaces in the shape of the casting to be made approximately equal to the casting itself, and supplemental means for supporting the trapway-formng portions of the casting until they are self-supporting.

7. A set of molds for casting a half-closet section comprising a half-mold, a body core and a foot core therefor, the half-mold and cores being so constructed and congured as to form between them spaces in the shape of the casting to be made approximately equal to the casting itself, and means on the mold and body core to insure correct registration therebetween.

8. A set of molds for casting vitreous closets in two parts comprising left and right half molds, a body core and a foot core for each mold, a foot overcast and an inflatable member adapted when inflated to support trapway-forming portions of the castings made in said molds, the molds being configured to produce two separate half closets unitable into an integral closet having the structure and appearance of a unitary article.

9. A set of molds as set Vforth in claim 6 wherein the supplemental means consists of an inflatable balloon-like member.

CHARLES W. LASCHENSKI. 

